Enhanced tantalum and niobium recovery from fine-grained low-grade Abu Dabbab ore using Falcon concentration and magnetic separation

Tantalum (Ta) and niobium (Nb) possess unique properties that make them invaluable across various industries. However, their similar chemical characteristics and natural co-occurrence challenge their separation. This study aims to optimize the recovery of Ta and Nb from fine-grained, low-grade Abu Dabbab tantalite ore (Egypt) using integrated Falcon centrifugation and magnetic separation. The beneficiation process commenced with gravity separation via a Falcon SB40 concentrator, which was optimized through a Box-Behnken design to assess the feed rate, fluidization water, and centrifugal field effects. Under optimal conditions (89.30 g/min feed rate, 4.40 psi fluidization water, 200 G centrifugal field), a concentrate grade of 2.00% Ta ₂ O ₅ and 0.705% Nb ₂ O ₅ was achieved, with recoveries of 85.70 and 84.35%, respectively. Subsequent magnetic separation using a Box-Mag Rapid LHW separator (2.0 T field intensity, 21.05% matrix loading, 11.40% pulp density) further enriched the concentrate to 6.22% Ta ₂ O ₅ and 2.24% Nb ₂ O ₅ , with recoveries exceeding 94%. Cassiterite (SnO ₂ ) was co-enriched to 17.50% (195-fold enrichment), while the albite and mica fractions were recovered as by-products. The characterization study confirmed the efficacy of the sequential process, yielding a high-grade concentrate. The combined approach demonstrates a scalable, efficient pathway for upgrading fine-grained, low-grade tantalite ores, achieving 250-fold enrichment ratios for Ta and Nb. This work underscores the viability of integrating optimized gravity and magnetic separation for the sustainable recovery of Ta and Nb critical metals, offering significant economic and technological benefits for resource utilization from complex ores.